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Ultra-Com 300 1
Eurotec Finishing Systems Limited Unit 4 Lockflight Buildings, Wheatlea Industrial Estate,
Wigan WN3 6XR
Phone: 01942 829 111 Fax: 01942 820 491
http://www.eurotecfinishing.com e-mail : [email protected]
ULTRA-COM 300 Portable Powder Coating Unit
INSTRUCTION MANUAL
DOCUMENT: ULTRA-COM 300 - Manual
DATE ISSUED: 27. September, 1999
ISSUE NUMBER: 1
Ultra-Com 300 2
Ultra-Com 300 3
CAUTION
This equipment can be dangerous unless
it is used in accordance with the rules
laid down in this manual.
Read this manual completely before
installing and operating the equipment.
Ensure all safety instructions and
procedures are correctly followed and
that all operators are fully trained.
IMPORTANT: All other manuals
relevant to components and equipment
of the installation must be followed.
Ultra-Com 300 4
Ultra-Com 300 5
CONTENTS
1. Title
2. Caution
3. Contents
4. Declaration of Conformity
5. Ultra-Com 300 Portable Powder Coating Unit
6. Specification, Ultra-Com 300
General Data
Weights and Dimensions
Electrical Data
Electrical Controls
Pneumatic Data
Pneumatic Controls
7. Assembly Instructions
8. Set Up Procedure
9. Operating Notes
10. End of Use Cleaning Procedure and Changing Colour
11. Do's and Don'ts
12. Fault Finding and Defects On Finished Product
13. Total Energy Control
14. Appendix
(i) Assembly Drawings and Parts Lists
(ii) Schematic Diagrams
Ultra-Com 300 6
EC Declaration Of Conformity
We, Eurotec Finishing Systems Limited declare that the following product,
Description: Portable Powder Coating Unit
Model: ULTRA-COM 300
Use: Electrostatic Powder Coating
was manufactured by ourselves and conforms with the following standard (s) and /
or other normative document (s):
EC Machinery Directive 89/392/EEC
EC Low Voltage Directive 73/23/EEC
EC Directive of Electromagnetic Compatibility 89/336/EEC
Electrostatic Painting and Finishing Equipment Using Flammable Materials
EN50 050:1986 and EN50 053:Part 2:1989
Signed on behalf of Eurotec Finishing Systems Ltd. by
Mr. D.H. Campbell
Technical Director
Eurotec Finishing Systems Limited
Unit 4 Lockflight Buildings, Wheatlea Industrial Estate, Wigan, WN3 6XR
Tel: 01942 829111 Fax: 01942 820491
V.A.T. Reg. No. 535 0123 87
Company No. 3008563 Registered In England
Ultra-Com 300 7
ULTRA-COM 300 PORTABLE POWDER COATING UNIT
GENERAL DESCRIPTION
The ULTRA-COM 300 Portable Powder Coating Unit is a compact self
contained electrostatic powder coating unit designed for laboratory use, on-site
demonstrations and powder test sampling.
The unit is housed in a rugged yet attractive black ABS carrying case. The
electrostatic and pneumatic control system is integrated in to the base section of the
case and the hinged lid compartment contains the manual gun, hoses and cables.
The ULTRA-COM 300 spraying capability is achieved through use of the state
of the art MG 300 manual powder gun. A robust well balanced powder gun with a
built in high voltage multiplier charging system utilising the unique "Total Energy
Control" system (TEC) developed by Eurotec. Once the maximum energy level on
the control panel has been set by the operator (The maximum settings available to the
user are 85kV and 50uA at the single point corona needle tip) the TEC system
automatically adjusts both the current and voltage enabling the operator to achieve
optimum spraying results. The TEC system minimises problems caused by back
ionisation and the Faraday cage.
Powder feed to the gun is from either a conical cup fitted directly onto the gun
via a special venturi nozzle section which replaces the standard nozzle, or a larger
cup which is secured to the side of the gun handle by means of a retaining bracket.
Powder flow for the larger cup is created using a venturi body section and controlled
by a built in air flow regulator. To give even more accurate control the air pressure
can be adjusted by the air pressure regulator mounted in the control panel of the unit.
The flexibility of the unit is further increased by the inclusion of 3 different
powder deflectors and a slotted cap which, combined with a variable forward air
supply to the nozzle enables the operator to control the spray pattern to suit the
components being sprayed. A blow down gun is also included to allow clean down of
components and the unit itself.
All in all the ULTRA-COM 300 is a self contained state of the art powder
coating unit which is totally portable and can be ready for use within minutes making
it ideal for powder sampling and small painting applications.
Ultra-Com 300 8
SPECIFICATION
General Data
Cup Nozzle Capacity 100 cubic centimetres (approx. 60 grams).
Cup Nozzle Mounting Replaces standard nozzle.
Standard Cup apacity 325 cubic centimetres (approx. 170 grams).
Standard Cup
Mounting
Retaining clamp and direct hose connection to powder
spigot on gun.
Powder Delivery
Rate
Variable to 400 gms. / min.
Operating
Temperature
5 degrees C (41 deg. F. ) to 40 degrees C (104 deg. F).
Length of Hoses &
Cables supplied
2 metres, airline supply, blowdown gun and gun supply.
2 metres, mains cable and trigger lead.
Powder Charging Single Point Corona Discharge Needle.
Weights and Dimensions
MG 300 hand gun weight:- 0.58kg
Cup nozzle weight (exc. deflector):- 90.2g
Cup and adapter weight (inc. hose, airline and clamp):- 258.2g
Unit weight (unpacked):- 6.5kg
Unit dimensions (closed and unpacked):- L265, W356, H154
Unit weight (packed):- 7.0kg
Unit dimensions (packed):- L290, W380, H180
Unit volume (packed):- 0.019 cubic metres
Electrical Data
Input Voltage 100-130/200-260 Volts, 50/60 Hz
single phase
Power Consumption 35VA
Input Current (Max.) 400mA at 115V, 200mA at 230V
Electrostatic Output Voltage (Max.) 10-85KV negative
Electrostatic Output Current 0-50uA
Ultra-Com 300 9
Electrical Controls
Mains Switch
- Control Panel
Rotary 2 position, ON/OFF (Green LED
indicates ON).
Electrostatic Switch
- Control Panel
Rotary 2 position, monitor uA or monitor KV.
Maximum Charge Control
- Control Panel
Rotary potentiometer, sets Max. level of charge
(Yellow LED indicates ON)
Electrostatic Meter
- Control Panel
Dual scale, 0-50uA or 0-100KV.
Mains Input
- Control Panel
Via connector (to IP65), on panel.
Trigger Output
- Control Panel
Via connector (to IP65), on panel.
Circuit Protection
- Control Panel
Miniature circuit breakers:-
0.6A Mains, Live.
0.6A Mains, Neutral.
Pneumatic Data
Input air pressure- Max. 7.0 bar (100 p.s.i.)
Input air conditioning Oil free to 0.1 p.p.m. and dry to 1.3 g/cubic Nm.
Air consumption ( Nominal ) 10.0 m3/hr. (6.0 c.f.m)
Input Connection Quick release stem fitting.
Pneumatic Controls
Air Input
- Control Panel
Mains air inlet connection.
Solenoid Switched Output
- Regulated
Regulated air supply to the gun.
Pressure Regulator &
Gauge
Provides a regulated output (2bar, 30 psi) to the
gun for repeatable powder control.
Solenoid switched output
- Non regulated
Provides a non regulated air supply to the gun, for
powder control using flow regulators built in to
the gun/cup attachments.
Non Switched Auxiliary
Output
Maintained unregulated air output for connection
of an air clean down gun (supplied).
Ultra-Com 300 10
ASSEMBLY INSTRUCTIONS FOR THE ULTRA-COM 300
WARNING THIS EQUIPMENT MUST BE EARTHED
NOTE:- Electrical/pneumatic circuit diagrams are given at the rear of this manual.
(1) Carefully remove units and components from packaging, and check contents
against packing list.
(2) Unclip fasteners on front of unit and open lid, this should reveal the coiled
airlines (which prevent the contents from displacing during transit). Remove
the airlines and release the inner lid container by removing the upper Velcro
fastener and carefully lowering. Inside the lid container one should find the
MG300 manual powder spray gun, the trigger lead assembly and the mains
lead assembly.
(3) Select either the cup nozzle or the cup adapter as the required apparatus and
follow the assembly instructions detailed in appendix (i).
(4) Once the gun is assembled fit the required deflector or slotted cap.
(5) Connect the airline(s) and trigger lead to the connectors on the handle/cup
adapter body of the gun as shown in appendix (i).
(6) Connect the free ends of the trigger lead and airline(s) to the control panel as
shown in appendix (i).
(7) Connect the main airline assembly to the incoming quick release air fitting.
(8) The cleandown airgun (supplied) is connected using a 6mm airline with a
quick release fitting (supplied).
(9) Connect the mains electrical socket on the mains lead onto the quick release
connector on the control panel of the unit. Before connecting the unit to the
mains supply firstly ensure the voltage selector is set correctly, either 230V or
115V
WARNING Under no circumstances should the voltage selector be set to a value lower
than the mains supply as damage may result.
NOTE:- The units are supplied set to 230V.
IMPORTANT
When fitting a plug to the mains lead (unit comes with plug fitted) it is
essential that it contains an earthing/grounding contact and that this is
connected.
Under no circumstances should this equipment be connected to a mains supply
which does not include an earthing/grounding wire and contacts. e.g.. 2 -Wire
extension leads as used for some domestic equipment MUST NOT BE USED.
NOTE:- The cable colour coding used for the Control Unit and its supplied mains
cable is as follows:-
Pole US/JAPAN U.K.
Live L Black Brown
Neutral N White Blue
Earth / Ground E Green Green/Yellow
Ultra-Com 300 11
NOTE:- For U.K. Equipment
The wire which is coloured GREEN and YELLOW must be connected to the terminal
in the plug which is marked with the letter E or by the earth symbol, or coloured
green or green and yellow. The wire which is coloured BLUE must be connected to
the terminal which is marked with the letter N or coloured black. The wire which is
coloured BROWN must be connected to the terminal which is marked with the letter
L or coloured red.
NOTE:-
The terminals used in the mains connector on the control panel of the unit are:-
POLE PIN No.
Live Pin 1
Neutral Pin 3
Earth / Ground Pin E
NOTE:-
The method of disconnection from the mains electrical supply is by removal of the
mains lead plug from its respective supply socket.
The unit is now ready for use.
Ultra-Com 300 12
SET UP PROCEDURE
NOTE:- Ensure the unit has been assembled correctly. If in doubt refer to the
assembly instructions detailed in this manual.
(1) Ensure that all switches are in the OFF position, and there is no powder in the
cup being used.
NOTE:- If the pressure regulator on the control panel is being used (see
airline connection illustration in appendix (i)) ensure it is properly closed (the
knob should be turned fully anti-clockwise). The knob of the pressure
regulator is released by pulling outwards and locked by pressing inwards.
(2) Turn on the 'MAINS ELECTRICAL' switch of the control unit. The green
LED above the switch will illuminate. (Diagrams in the appendices of this
manual indicate the function and location of the various switches, regulators,
connectors etc. on the control panel).
(3) With the spray gun pointing into an extracted spray booth, operate the trigger
of the gun and open the appropriate flow regulator(s) until a hissing is heard
from the nozzle of the gun.
(4) Fill the powder receptacle being used with the desired amount of powder.
(5) With the gun pointing into an extracted booth press the trigger, open the flow
regulator(s) until the desired powder flow is obtained. This air supply should
be kept to a minimum consistent with smooth powder flow to prevent powder
from being ejected into the surrounding air.
NOTE:- The flow regulator on the control panel has a locking facility,
operated by pushing the adjusting knob inwards, which may be used to lock
the flow setting.
(6) Check that the regulator, the solenoid valve and the electrostatic generator
(see (9)) are operating when the trigger is pulled.
NOTE:- The set maximum KV level will be displayed on the KV meter
without the need to operate the trigger of the gun. The uA level will only be
displayed on the uA meter when the gun is in use.
(7) Adjust pressures (using regulator screw on cup adapter body or regulator on
control panel) as necessary to ensure an even flow of the desired quantity of
powder from the gun.
(8) The small flow regulator on the left hand side of the spray gun is used to
control the air flow which passes forward through the nozzle. This air flow
must be adjusted to ensure that the electrode and spreader faces are
maintained clean. Further adjustment of the air flow allows the operator to
alter the size and shape the powder cloud or the velocity of powder from the
slotted nozzle.
(9) With the charge control potentiometer turned anti-clockwise, turn the
electrostatic switch to the position marked kV. The yellow LED above the
charge control potentiometer will illuminate dimly, and the electrostatic meter
will indicate approximately 22 kV. Slowly turn the charge potentiometer
clockwise and the brightness of the yellow LED will increase and the pointer
of the electrostatic meter will rise to approximately 85 kV when the
potentiometer is fully clockwise.
With the gun pointing into an extracted spray booth, trigger the unit and
slowly move the nozzle of the gun close to an earth point or the product. As
the nozzle moves closer than approximately 280 mm it will be seen that the
kV level indicated on the meter will reduce progressively as the nozzle is
moved closer to earth. Repeat this procedure with the electrostatic switch set
Ultra-Com 300 13
to the uA position and it will be seen that as the nozzle moves to within
approximately 280 mm from earth, the current will rise progressively to
approximately 50 uA. As the nozzle continues to be moved closer, the current
then falls progressively. Refer to the graph showing the typical electrostatic
discharge characteristics with respect to the distance from earth.
NOTE:- The discharge current and voltage will be dependent on the proximity
of the spray gun discharge needle to earth. When setting the maximum
discharge voltage, the spray gun discharge needle should be placed at least
300 mm. from earth.
GENERAL NOTE:-
An approved mask should always be worn when spraying.
GENERAL OBSERVATIONS:-
It is essential that all substrates and jigs are clean and that there is a good earth /
ground to the workpiece to ensure maximum powder attraction.
Powder spraying is best performed by slow motions of the spray gun as opposed to
the faster gun movements often associated with liquid paint spraying. Higher
powder emissions do not necessarily mean faster coating or better penetration into
corners and recesses. In practice it can often cause the opposite effect and produces
products with a poor finish.
Similarly, high electrostatic discharge currents or voltages do not necessarily mean
faster or more efficient coating. Again, in practice, they can cause the opposite effect
and produce products with a poor finish.
OPERATING NOTES
(1) This equipment can be dangerous unless it is used in accordance with the
rules laid down in this manual.
(2) Ensure that the equipment is properly earthed/grounded. Refer to assembly
instructions item (9).
(3) The electrical supply to the electrostatic gun and control unit should be
interlocked with the spray booth extraction system such that spraying cannot
be carried out unless the exhaust ventilation system is in operation. The
efficiency of the exhaust ventilation system should be checked regularly.
(4) All conductive structures within the vicinity of the spray area shall be bonded
together with the earth terminal of the gun control unit to the protective earth
of the system.
(5) The equipment operates by electrostatically charging the powder by means of
a high voltage corona discharge at the nozzle of the gun. This electrostatic
discharge can seriously damage other electronic equipment if it is sited in
close proximity and not suitably protected.
(6) It is essential that all jigs and workpieces are adequately earthed. The
workpiece shall have a resistance to earth of no greater than 1 Mohm. This
should be checked regularly. If the earthing is not adequate, it can result in:-
a) Poor coating.
b) Sparks between the product and jigs, which can constitute an ignition or
explosion hazard.
c) Radio and TV interference from sparks between the product and jigs. This
interference may also affect computer systems and process controllers.
(7) Ensure that the air supply is clean and dry. Using a wet and dirty or poorly
maintained air supply may invalidate warranty. Refer to the pneumatic
specifications.
Ultra-Com 300 14
END OF USE CLEANING PROCEDURE
IMPORTANT WHENEVER COMPRESSED AIR IS USED FOR
CLEANING EQUIPMENT THIS OPERATION MUST BE
CARRIED OUT IN AN EXTRACTED SPRAY BOOTH. AN
APPROVED MASK AND EYE PROTECTION SHOULD
ALWAYS BE WORN WHEN USING A COMPRESSED AIR
CLEAN DOWN GUN.
(1) Turn the mains switch to the OFF position.
(2) Empty remaining powder from the cup being used, and remove from the spray
gun (see assembly instructions and diagrams in the appendices).
Clean the cup and other associated components with compressed air and wipe
clean.
(3) Remove the nozzle from the front of the gun and clean internally with
compressed air and externally with a clean cloth.
(4) Re-fit the nozzle nut securely in place.
(5) Clean case internally and externally with compressed air and wipe down with
a clean cloth if necessary.
(6) Ensure that electrical and pneumatic supplies to the unit are switched off and
disconnect from the unit.
(7) Replace the standard nozzle, cup nozzle/cup and adapter and the deflectors to
the appropriate spaces in the lower moulding.
(8) Coil the airlines and electrical leads.
(9) Replace the gun and coiled mains and trigger leads into the lid section of the
case.
(10) Place the coiled airlines over the components section of the case so that they
will be held in place when the lid is closed, for security during transit.
CHANGING COLOUR
NOTE:- Follow the cleaning procedure excluding sections regarding packing the
equipment.
In short clean all of the gun and cup components internally and externally with
compressed air and if necessary wipe down with a clean cloth. Once cleaned to a
satisfactory level a different colour may then be introduced into the system.
Ultra-Com 300 15
DO's And DON'Ts
DO's
(1) Ensure that the equipment is operated by trained personnel only.
(2) Ensure that the equipment is serviced regularly by qualified personnel. All
repairs and maintenance shall be carried out by qualified personnel only, in
accordance with the manufacturers instructions. Repairs must be carried out
at the instigation of the operator when faults or defects are detected. Repairs
must not be performed in hazardous areas and must not compromise safety
standards.
(3) Ensure that the operator is correctly earthed. If overalls are worn, they should
be anti-static or non-insulating. If gloves are worn, they should be anti-static
or non-insulating. If this is not possible, gloves with the palms removed may
be used. Footwear intended for use by operators shall be anti-static or non-
insulating and shall comply with the requirements of ISO 2251 / BS 5451 or
equivalent. Shoes with leather soles are usually adequate.
(4) Ensure that the operator wears suitable respiratory equipment and or
protective clothing. All personnel working in a powder-laden atmosphere
should wear similar equipment.
(5) Ensure that the operator wears suitable eye protection e.g. goggles or a visor
(in addition to a respiratory mask) when using a compressed air clean down
gun as particles in the airstream can damage eyes.
(6) Avoid skin contact with powders where possible as some powders may cause
skin irritation.
(7) Wash hands and face after work and prior to eating or drinking.
(8) Keep floors and equipment within 5 metres of the spray area clean using a
suitable industrial vacuum cleaner.
(9) Keep light fittings and all other electrical equipment clean.
(10) Regularly check the effectiveness of dust/powder collectors and extraction
filters and that recycled air is clean.
(11) Regularly check the earthing of electrical equipment and manually operated
spray guns.
(12) Regularly check the earth bonding of all conductive electrical enclosures and
all conductive structures such as floors, walls, ceilings, fences, conveyors,
powder containers etc. within the vicinity of the spray area. These shall be
bonded together with the earth terminal of the high voltage generator to the
protective earth system of the electrical supply. Electrostatic grounding
should comply with EN 50053.
(13) Ensure that all jigs and work pieces are adequately earthed. Each workpiece
shall have a resistance to earth of not greater than 1 Mohm. This resistance
shall be checked regularly.
(14) Ensure that correct cleaning procedures are followed. See " Cleaning
Procedures".
(15) Ensure that powders are processed in compliance with the powder
manufacturers instructions. Special care should be taken with powders
containing metallic pigments.
(16) Regularly check the compressed air supply to ensure that it is clean and dry.
Ultra-Com 300 16
DON'TS
(1) The operator must not wear insulating gloves, clothing or footwear.
(2) Do not smoke in areas where powder coating is being carried out or in areas
where powder is stored.
(3) Do not eat or drink in areas where powder coating is being carried out or in
dust-laden atmospheres.
(4) Do not spray into areas which are not properly extracted. The direction of
airflow should always be from behind the operator. It is recommended that
airflow velocities over the face area of a booth opening should be in excess of
0.5 metres/sec.
(5) Do not use compressed air for cleaning skin and clothing as it can penetrate
the skin causing embolisms. Use a suitable industrial vacuum cleaner for
clothing and wash skin with water.
(6) Do not point compressed air clean down guns towards body orifices (mouth,
ears etc.).
(7) Do not enter spray booths when in operation.
(8) Do not attempt to make any internal repairs as there is a risk of injury. Any
repairs made to the equipment other than those made by qualified personnel
will invalidate any warranty on the equipment.
(9) Do not operate the equipment in environments which exceed the operating
parameters of the unit, as this may result in damage to the equipment and
subsequently invalidate any warranty.
NOTE:- The workplace must be kept tidy and well organised to reduce the risk of accidents.
Good illumination, protection from any damp environment and correct storage of
materials will assist the operator to maintain concentration and an awareness of
potential hazards.
NOTE:- Before starting to clean the spray gun or carrying out any other work in the spraying
area, the high voltage supply shall be switched off in such a manner that it cannot be
re-energised by operating the trigger of the spray gun.
Ultra-Com 300 17
FAULT FINDING
UNIT WILL NOT OPERATE (No LED's will illuminate)
(1) Check that mains connector is fitted to the control panel of unit.
(2) Check that unit is connected to a suitable mains electrical supply and is
switched on.
(3) Check that miniature circuit breaker (automatic fuses) on the control panel of
the unit have not been tripped. If one or more has, then press to reset. If it
trips again, switch off unit and refer to an authorised distributor or service
agent.
UNIT WILL NOT OPERATE (LED's will illuminate)
(1) Check the trigger connections at the gun and on the control panel of the unit.
(2) Check that the trigger switch in the gun is operating. Depress the trigger and
an audible click should be heard if the trigger switch is operating.
(3) Check that the voltage selector switch is set to the required voltage. The unit
is supplied pre-set to 230 volts. If the local supply is between 100V and
130V, reset the selector switch on the control panel to 115 volts.
WARNING DO NOT set the voltage selector switch to 115V if a higher supply
voltage is being applied as damage may result.
NO POWDER DELIVERY
(1) Check air supply to unit.
(2) Check that powder container is not empty.
(3) Check that the internal solenoid valve is operating by depressing gun trigger
when an audible click should be heard. If it is not, check the trigger
connections at the gun and on the control panel of the unit.
(4) Check for blocked powder hose section (cup adapter).
(5) Check for blockage in venturi body section and gun.
POWDER DELIVERY INTERMITTENT OR SURGING
(1) Check that there is sufficient powder in the container.
(2) Check air pressure and adjust if necessary.
(3) Check for any partial blockages in the powder hose section, venturi body
section, or gun. Blockages in powder paths may be caused by damp powder if
the air supply contains more than the permitted level of moisture.
(4) Check that the venturi body is sealing properly with its associated
components.
(5) Check that the powder is not damp. If it is, it may not move down to the
suction point and lumps may form in the powder causing partial blockages
and 'spitting' from the nozzle of the gun. Powder may become damp if left for
long periods in an open container.
Ultra-Com 300 18
POWDER DOES NOT ADHERE TO WORKPIECE
(1) Check that electrostatic switch is set to either the uA or kV positions. The
yellow LED should be illuminated.
(2) Check the setting of the charge control potentiometer and that an electrostatic
charge is present at the discharge electrode needle of the gun.
(3) Check that the workpiece is properly earthed / grounded.
(4) Check that the compressed air supply is clean and dry. Dirt and moisture
trapped inside the gun may cause a loss of electrostatic charge to earth, if this
is occurring the units warranty may be invalidated
DEFECTS ON FINISHED PRODUCT
CONTAMINATION OF SURFACE WITH SPECKS OF OTHER COLOURS
(1) Application equipment inadequately cleaned after using previous powder.
(2) Airborne powder of different type within a contaminated spraybooth, or
sucked in from dirty surroundings.
(3) Reclaimed powder contaminated with other powders from within the reclaim
system e.g. ductwork, cyclone, booth etc.
(4) Airborne contamination within the oven.
(5) Dust or dirt dislodged from jigs or conveyor.
(6) Dusty environment before or after coating.
LUMPS OR PROTRUSIONS ON SURFACE
(1) Dirty or contaminated powder.
(2) Dirty or contaminated substrate (workpiece)
(3) Rusty substrate
(4) Dusty environment before or after coating.
(5) Dust or dirt in oven.
(6) Dust or dirt dislodged from jigs or conveyor.
HEAVY 'ORANGE PEEL'
(1) Applied coating is too thick.
(2) Incorrect cure cycle and/or temperature.
(3) Inferior quality or powder.
FISH EYES
(1) Contamination of substrate.
(2) Contamination of powder.
(3) Contamination of compressed air supply.
Ultra-Com 300 19
NOTE:- Contamination may be caused by airborne vapour such as wet paint, airline
or conveyor oil or stripping facilities.
Silicones and acrylic paints are the worst offenders and can contaminate the powder
and / or substrate.
CRATERS AND VOIDS
(1) Poor cleaning of substrate e.g.. trapped oils or solvents.
(2) Wet components e.g.. water trapped in corners or joints.
(3) Contamination of powder.
(4) Contamination of substrate.
PIN-HOLING AND BUBBLES
(1) Porous substrate e.g. expansion or air or solvents from porosity or cavities in
castings during curing cycle.
Pre-heating of the workpiece may help to overcome this.
(2) Excessive electrostatic charge applied to the powder. To overcome, reduce the
discharge current.
(3) Rusty substrate.
(4) Contamination of substrate, powder, air supply or from dirty surroundings.
(5) Excessive moisture in compressed air supply. Refer to pneumatic data in
specifications.
Ultra-Com 300 20
TOTAL ENERGY CONTROL
The "Total Energy Control" system developed by Eurotec is used to set the discharge
energy of the spray guns corona needle up to a maximum of 85kV and 50 µA.
The maximum current generated is limited to 50 µA (as with existing current control
equipment) but now both the current and voltage are reduced as the gun approaches
the product. Rather than controlling just the current or the voltage the operator is
now able to control the total energy output from the gun.
In free air, away from the influence of any earthed objects the maximum discharge
current will be 20 µA when the Discharge potential is set to maximum 85 kV. As the
gun is moved within one meter of the product the current starts to rise and, in
tandem, the control circuit reduces the voltage. This process continues as the gun is
moved closer to the product until a point is reached at which the energy is limited by
the setting of the control potentiometer. At this point the Total Energy Control
system rapidly reduces the energy output from the gun as it further approaches the
product.
The ability to control the output energy of the gun allows the operator to take the gun
right in to corners and recesses and still effectively charge powder at very low
electrostatic outputs. High film builds are achieved with superior finishes and no
surface disruption, whilst very significant improvements are noted in the ability to re-
coat previously coated products.
KV/µA
Centimetres from Earth
0
100
100
50
50
10
20
30
40
60
70
80
90
10 20 30 40 60 70 80 90
DENOTES VOLTAGE (kV)
DENOTES CURRENT (µA)
Ultra-Com 300 21
APPENDIX (i)
ASSEMBLY DRAWINGS
& PARTS LISTS
Ultra-Com 300 22
ULTRA-COM 300 Portable Unit General Assy
Part.No. 5020001 Illustration No. 6000059
0.6A0.6A
1
2
67
38
24 25
24 25
27 29
39
32 33 34 35
26
30 312 2
57
55
ULTRA-COM 300Po rtab le Po wd er Co atin g Un it
17
88 87 48
21 8415 2015 19 15 184
3
53
8
43
27
40
36
523
Ultra-Com 300 23
ULTRA-COM 300 Portable Unit General Assy
PARTS LIST
Item Part No. Description Qty.
1 3016090 Cup Nozzle Assy 1
2 3016100 Cup Adaptor Assy 1
3 3015045 Slotted Cap Assy 1
4 3016005 Nozzle Assy 1
5 3000040 Spreader 1
6 3000039 Spreader 1
7 5020004 Lab Unit Overlay, 300 series 1
8 5020010 Top Panel, Lab Unit, 300 series 2
9 5020011 Lid Panel, Lab Unit 300 Series 1
10 5020012 Gauge Coupling, Lab Unit 300 Series 1
11 5020013 Chassis, Lab Unit 300 Series 1
12 5020014 Solenoid Fixing Bracket, Lab Unit 300 1
13 5020016 Nut Plate Long, Lab Unit 300 Series 2
14 5020017 Nut Plate Short, Lab Unit 300 Series 2
15 5020018 Pillar, Deflector Mounting, Lab Unit 300 3
16 5020019 Label Outer, Lab Unit 300 Series 1
17 5020020 Label Inner, Lab Unit 300 Series 1
18 3015047 Deflector Assy Small 1
19 3015048 Deflector Assy Medium 1
20 3015049 Deflector Assy Large 1
21 9000113 Earth Terminal 1
22 2001010 Transformer 1
23 2000026 Regulator Assembly 1
24 9001528 Switch Contact Block 2
25 9001527 Switch Actuator 2
26 9001053 Voltage Selector 1
27 9000005 Led Housing 3mm 3105 2
28 9000095 Led Green 1
29 9000096 Led Yellow 1
30 9000016 Circuit Breaker 2
31 9000019 Boot For Circuit Breaker 2
32 9000051 Potentiometer 1
33 9000002 Collet Knob, Black Type K151-250 1
34 9000004 Nut Cover, Black Type N151 1
35 9000003 Potentiometer Cap, Yellow 1
36 9001595 Q.D Air Connector, Female 6/4 Bulkhead 3
37 9000038 Solenoid Valve 1
38 9001083 Q.D Air Connector, Male 1/8 BSPMP 1
Ultra-Com 300 24
Continued:-
Item Part No. Description Qty.
39 9001596 Elbow, 1/8BSPFP - 6mm PI 3
40 9000120 Panel Mounting Base 2
41 9000013 Socket Connector 4 Pin +E 1
42 9000011 Plug Connector 3 Pin + E 1
43 9001526 Blow Down Gun 1
44 9000105 Stud 1
45 9000036 Twin Banjo Body 2
46 9001531 Banjo Bolt 3/8 BSP Single 2
47 2020054 PCB,Generator Board, Lab Unit 300 Series 1
48 2020024 Pressure Gauge, DIA 40mm, 30 PSI 1
49 9001156 Pillar 4
50 9000077 Connector CN-M5-PK-4 1
51 5020021 Connector Earthing Plate 1
52 5020006 Earth Lead Assembly, Lab Unit 300 Series 1
53 9001521 Case, ABS, Sealed, 613, Black 1
54 9000070 Foam Sealing Tape 1.3m
55 3016002 MG300 MK11 Manual Powder Gun Assy 1
56 5020007 Air Line Assembly, Lab Unit 300 Series 2
57 2020015 Meter 1
58 9001536 Connector, Disc Drive, Plug Free 1
59 9001537 Connector, Disc Drive, Socket Free 1
60 9000569 Screw, M4 x 20, CSK, SKT, HD, Black 8
61 9000804 Nut, M4 Nyloc 4
62 5020009 Powder Gun, Cable Assy, Lab Unit 300 1
63 5020022 Mains Lead Assy, Lab Unit 300 Series 1
64 9000168 Tubing, 6mm O.D. x 4mm I.D. Black 1.5m
65 9001534 Feet, Self Adhesive 4
66 9000560 Screw, M4 x 12, CSK, SKT, HD. Black 7
67 9000452 Cable, 6 Core, 16/0.2, Unscreened 0.7m
68 9000462 Cable, 4 Core, 16/0.2, Unscreened 1.38m
69 9000424 Wire, Brown, 0.5mm SQ, 16/02, Trirated 1.05m
70 9000425 Wire, Blue, 0.5mm SQ, 16/0.2, Trirated 1.05m
71 9000429 Wire, Grn/Yell, 0.5mm SQ, 16/0.2, Trirated 1.88m
72 9000427 Wire, Orange, 0.5mm SQ, 16/0.2, Trirated 0.38m
73 9000437 Wire, White, 0.5mm SQ, 16/0.2, Trirated 0.38m
74 9000468 Wire, Red, 7/0.2 0.15m
75 9000469 Wire, White, 7/0.2 0.15m
76 9001547 Mounting Blade, 45 Deg, 0.25IN PCB 3
Ultra-Com 300 25
Continued:-
Item Part No. Description Qty.
77 9000022 Cable Tie 15
78 9000550 Screw, M4 x 8, Cap, HD, Black 1
79 9000049 Terminal, Spaded, Large 8
80 9000050 Terminal, Spaded, Small 7
81 9000142 Terminal, Cover, Small 7
82 9000141 Terminal, Cover, Large 8
83 9000047 Sleeve, Rubber, H15 12
84 9000046 Solder Tag, 2BA 1
85 9000048 Sleeve, Rubber, H12 7
86 9001541 Nipple, M5 Hose - 4mm Tube 1
87 9000008 Base, Cable Tie 2
88 9000203 Tubing, 4mm O.D x 2.5mm I.D. PU, Black 0.15m
89 9001551 Velcro, Loop, 20mm x 5m 0.16m
90 9001552 Velcro, Hook, 20mm x 5m 0.28m
91 9001553 Tape, Insulating, Black Cloth 0.18m
92 9001561 Bulkhead, 1/8BSPFP -6 mm PI 1
93 9001597 Elbow, 6mm Plug In - 6mm PI 1
Ultra-Com 300 26
Cup Nozzle General Assembly
Part No. 3016090 Illustration No. 6000061
Item Part No. Description Qty.
1 3016096 Electrode, Cup Nozzle 1
2 3002031 Cup Small 1
3 3016091 Jet, Cup Nozzle 1
4 3016093 Body, CupNozzle 1
5 3016092 Venturi Insert, Cup Nozzle 1
6 3016098 Washer, HT Contact Assy, Cup Nozzle 1
7 3016097 HT Contact Spring Assy, Cup Nozzle 1
8 9000518 Screw, M3 x 5, HT Contact 1
9 9001058 O-Ring, BS No. 109 2
10 3015023 Washer, HT Contact 1
SECTION A - A
4 56
1
78
10 9
2
A
3
A
Ultra-Com 300 27
Cup Nozzle Assembly Instructions Illustration No. 6000064
Step 1)
Separate the nozzle jet from
the nozzle bodysimply by
easing the two
components apart.
Step 2)
Once separated insert
the nozzle jet section
into the nozzle nut,
then secure the
nozzle nut onto
the barrel.
Step 3)
Once the nozzle nut is secured
push the cup section onto the
end of the jet and into the the
nozzle nut as far as it will go
to ensure good
electrical continuity.
NOZZLE JETNOZZLE BODY
NOZZLE NUT
FULLY ASSEMBLED CUP NOZZLE ON M G300
CHOICE OF SPREADER SIZES
Ultra-Com 300 28
Cup Adaptor Assembly
Part No. 3016100 Illustration No. 6000062
Item Part No. Description Qty.
1 3016107 Lid, Cup Adaptor 1
2 3016104 Cup Body, Cup Adaptor 1
3 3016103 Funnel, Cup Adaptor 1
4 3016105 Screw, Regulator, Cup Adaptor 1
5 3016101 Body, Cup Adaptor 1
6 3016102 Venturi, Cup Adaptor 1
7 3016106 Powder Stub, Cup Adaptor 1
8 3016109 Sleeve Assy, Cup Adaptor 1
9 9000575 Screw, M4 x 12, Slt. Thumb Hd, Nylon 1
10 9001533 O-Ring, 11.6 x 2.4 1
11 9000071 O-Ring, 5.28 x 1.78 1
12 9001532 O-Ring, BS No. 032 1
13 3016108 Cup Body Clamp (Retaining Bracket) 1
14 9000366 Equal Tee, Push In Fitting 1
15 9001672 M6 Hose Elbow, 6mm Tube, Miniature 1
16 9000168 Tubing, 6mm OD x 4mm ID, Black 0.13m
INSER T C UP ADAPTOR FUNNEL
INTO THE CUPB ODY FR OM THIS
END OF THE C UP B ODY.
ENSUR E C UP ADAPTOR FUNNEL
LOC ATES INTO GR OOVE ON THE
C UP B ODY B ASE AS SHOW N.
1
2
3
4
5 10 6
8
9
12
11
1.
2.
SH O W N SLIG H TLY RO TA TED
A IR FITTIN G S A N D CO N N ECTO RS
RETA IN IN G BRA CK ET
7
Ultra-Com 300 29
Cup Assembly Instructions Illustration No. 6000076
To fit standard nozzle:
1. Unscrew nozzle nut from gun.
2. Locate standard nozzle into
nozzle nut and push fully in.
3. Screw nozzle nut firmly back onto gun body.
4. Select either the slotted cap or one of the deflectors and push
onto nozzle end.
Note:-
The assembly intructions are for right handed operators however the cup
may be mounted on either side of the gun allowing for left handed users.
Step 1)
Locate rubber hose connector onto
powder spigot on handle
of gun and push fully on.
Step 2)
Loosen mounting
screw located on side
of gun (black plastic
head) and slide
retaining bracket
mount between gun
and screw, then
tighten screw to
secure cup assembly
to the gun.
Step 3)
Unscrew airline clamp
screw, located on base of
handle, and slide over
the airline from the
cup adapter body.
Then push airline fully
onto the airline tail and
screw the clamp screw
back onto the air
fitting to secure the
airline in place.
SLOTTED CAP DEFLECTORS
NOZZLE NUTSTANDARD NOZZLE
STEP 1
STEP 2
STEP 3
(BLACK PLASTIC HEAD)
RETAINING BRACKET
POWDER
AIRLINE
AIRLINE
MOUNTING SCREW
RUBBER HOSE
CONNECTOR
SPIGOT
CLAMPSCREW
Ultra-Com 300 30
C1
C2
R1
R2
D1
TR
1C
3
00
+
-
+
-
M+
00
TT
12
34
11
56
7 13
15
89
16
12
18
14
17
2
10
MG
30
0 M
an
ual
Pow
der
Gu
n
Gen
era
l A
ssem
bly
Pa
rt N
o. 3
016
002
Il
lust
rati
on N
o. 6000092
Ultra-Com 300 31
MG 300 Manual Powder Gun General Assembly
PARTS LIST
Item Part No. Description Qty.
1 3015045 Slotted Cap Assy. 1
2 3015047 Deflector Assy. Small 1
3 3015048 Deflector Assy. Medium 1
4 3015049 Deflector Assy. Large 1
5 3016005 Nozzle Assembly 1
6 3016006 Barrel Assembly 1
7 3016007 Handle Assembly 1
8 3016008 Oscillator PCB Assy. 1
9 3016010 Gun Hook Assembly 1
10 3016011 HV Multiplier Assembly 1
11 3016012 Nozzle Nut Assembly 1
12 3016027 Rear Cap 1
13 3016034 Air Connector Nut 1
14 3016042 Label, Type 1
15 3016083 Label, Rating 1
16 9000512 Screw, M3 x 8, Pozi Pan Head 1
17 9000571 Screw, M4 x 40, Ctsk skt head Blk 2
18 3016063 Locating Bush PCB 2
Ultra-Com 300 32
11
12
2
24
26
23
22
65
107
21
51
23
98
41
71
62
5
13
13
14
18
19
2
MG
30
0 M
an
ual
Pow
der
Gu
n
Ha
nd
le A
ssem
bly
, P
art
No
. 3
016
007
Il
lust
rati
on
No
. 60
000
93
Ultra-Com 300 33
MG 300 Gun Handle Assembly PARTS LIST
Item Part No. Description Qty.
1 3016032 Air Regulator Orifice 1
2 9001379 Circlip 1
3 3016023 Air Regulator Body 1
4 3016022 Air regulator Needle 1
5 3016029 Powder Elbow 1
6 3016020 Powder Bore Insert 1
7 9001380 Air Fitting 1
8 9001376 O-Ring, 2.2x1.6 1
9 9001328 O-Ring, BS No. 011 1
10 9001378 3mm Airline 0.115
11 3016028 Powder Tube 1
12 3016031 Powder Tail 1
13 3016060 Handle Moulding, Left Hand Side 1
14 3016033 Air Fitting 1
15 3016045 Microswitch Assembly 1
16 9001375 Spring, Compression 1
17 3016018 Trigger Moulding 1
18 3016044 Connector Assembly 1
19 9000513 Screw, M3x20, Slt Csk Hd, Black 2
20 9000510 Screw, M3x6, Pan Head 1
21 3016062 Washer, Conductive, Plastic 1
22 9001377 O-Ring, 13.0x1.0 1
23 9001434 M3 Threaded Brass Insert 5
24 3016026 Handle Moulding, Right Hand Side 1
25 9000318 O-Ring, BS.007 1
26 9000375 Spring Compression 1
Ultra-Com 300 34
AG
/MG
300
Po
wd
er G
un
s
Ba
rrel
Ass
emb
ly, P
art
No
. 30
160
06
Il
lust
rati
on
No
. 60
000
94
Qty
1
1
1
1
1
2
1
1
De
sc
rip
tio
n
HT
Co
nta
ct P
in
HT
Bar
rel
Ty
pe
85
HT
Co
nta
ct R
od
HT
Co
nta
ct N
ut
Sp
ring
, C
om
pre
ssio
n
Inse
rt,
Th
read
ed
Air
Co
nnec
tio
n P
in
HT
Pin
Ret
ainin
g S
crew
Pa
rt N
o.
30
15
02
4
30
16
05
7
30
16
03
8
30
16
03
9
90
01
37
5
90
01
43
5
30
21
02
2
30
16
01
3
Item
1.
2.
3.
4.
5.
6.
7.
8.
25
41
3
6
7
8
Ultra-Com 300 35
Con
tro
l P
an
el S
ym
bo
ls E
xp
lan
ati
on
UL
TR
A-C
OM
30
0
Illu
stra
tion N
o. 6000077
0.6A
0.6A
0.6A
0.6A
GU
N T
RIG
GE
R L
EA
D C
ON
NE
CT
OR
MA
INS
SUPP
LY
CO
NN
EC
TO
R
AU
XIL
IAR
Y A
IR O
UT
LE
T,
SWIT
CH
ED
NO
N R
EG
UL
AT
ED
RE
GU
LA
TE
D A
IR O
UT
LE
T (C
ON
TR
OL
LE
D
AIR
SU
PPL
Y IN
LE
T C
ON
NE
CT
OR
uA/K
V S
EL
EC
TO
R (D
ET
ER
MIN
ES
CH
AR
GE
CO
NT
RO
L P
OT
EN
TIO
ME
TE
R
MA
INS
"ON
" L
ED
IND
ICA
TO
R
EL
EC
TR
OST
AT
ICS
"ON
" L
ED
IND
ICA
TO
R
CIR
CU
IT B
RE
AK
ER
S, P
USH
TO
RE
SET
AIR
RE
GU
LA
TO
R C
ON
TR
OL
EA
RT
HIN
G P
OIN
T
MA
INS
"ON
"/"O
FF"
SWIT
CH
(CO
NT
RO
LS
SOL
EN
OID
VA
LV
E)
NO
N R
EG
UL
AT
ED
& N
ON
SW
ITC
HE
D
AIR
OU
TL
ET
WIT
H R
EG
UL
AT
OR
ON
CO
NT
RO
L P
AN
EL
)
TH
E M
ET
ER
DIS
PLA
Y)
Ultra-Com 300 36
Airline Connection Variations ULTRA-COM 300
Cup Nozzle & Cup Adaptor Illustration No. 6000067
1. Powder output controlled by regulator screw on side of gun
2. Powder output controlled by regulator on control panel
AIR IN
REGULATOR SCREW
CONNECT TO AIRLINE TAIL ON HANDLE OF GUN
0 .6 A0 .6 A
0 .6 A0 .6 A
REGULATOR
AIR IN
CONNECT TO AIRLINE TAIL ON HANDLE OF GUN
FULLY OPEN REGULATOR SCREW
Ultra-Com 300 37
3. Powder output controlled by regulator on control panel
4. Powder output controlled by regulator screw on cup adaptor body
5. Powder output controlled by regulator on control panel with
independant air supplies to nozzle & cup
CONNECT AIRLINE TO T-PIECE
FULLY OPEN REGULATOR SCREW
NOZZLE AIR CONTROL
REGULATOR
AIR IN
0 . 6 A0 . 6 A
REGULATOR SCREW
CONNECT AIRLINE TO T-PIECE
AIR IN
NOZZLE AIR CONTROL
0 . 6 A0 . 6 A
CONNECT TO AIRLINE TAIL ON GUN HANDLE
AIR IN
CONNECT TO CUP
NOZZLE AIR CONTROL
REGULATOR SCREW FULLY OPEN
ADAPTOR AIRFITTING
0 . 6 A0 . 6 A
Ultra-Com 300 38
APPENDIX (ii)
SCHEMATIC DIAGRAMS
Ultra-Com 300 39
ULTRA-COM 300 PORTABLE UNIT
Pneumatic Diagram Illustration No. 6000066
24V d.c
AUX.
IN
0-2 BAR
SWITCHED AIR OUTPUT
SWITCHED, REGULATED AIR OUTLET
Ultra-Com 300 40
ULTRA-COM 300 Portable Unit
Wiring Diagram Illustration No. 6000060
24v
115v
115v
1 2 3 4
VO
LT
AG
ES
EL
EC
TO
R
0.6A
0.6A
MA
INS
SW
ITC
H
C C
NO
NO
TR
AN
SF
OR
ME
R
CO
NN
EC
TO
R
PL
1
24V
AC
PL
6PL
2
C/P
OT
uA
KV
OF
F
PL
3
PL
4
0V
WH
ITE
RE
D
BR
N
BL
BR
N
BL
GR
EE
N/Y
EL
LO
W
SO
CK
ET
MA
INS
IN
LE
T
GR
EE
N L
ED
POW
ER
ON
PL
5
10
KC
ON
TR
OL
POT
24V
DC
SO
LE
NO
IDV
AL
VE
P0
E/S
uAK
V0
+v
e
BL
AC
K
YELLOW
BLUE
ME
TE
R
YE
LL
OW
LE
DST
AT
ICS
ON
GTMO
RE
D
GR
EE
N
WH
ITE
RE
D
BL
UE
WH
ITE
GR
N
BL
UE
BL
UE
RE
D
WH
ITE
GREEN
WHITE
YELLOW
BLACK
RED
BLUE
E
GR
EE
N/Y
EL
LO
W
CH
AS
SIS
BR
AC
KE
TE
AR
TH
AS
SE
MB
LY
GR
EE
N/Y
EL
LO
W
SO
CK
ET
CO
NN
EC
TO
R4
PIN
+ E
SWIT
CH
AC
TU
AT
OR
-ve
BR
EA
KE
RS
CIR
CU
IT
3
1 2
BR
N
BL
432
1
FR
ON
T P
AN
EL
EA
RT
H P
OS
TC
ON
NE
CT
OR
EA
RT
HIN
G P
LA
TE
GR
EE
N/Y
EL
LO
W
GR
EE
N/Y
EL
LO
W
RE
D
PL
7
0v10
v24
vV
Ultra-Com 300 41
NOTES:
NOZZLE JET NOZZLE BODY NOZZLE NUT
